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Metals
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Wire Arc Additive Manufacturing of Metallic Components
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Wire Arc Additive Manufacturing of Metallic Components

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: closed (31 July 2022) | Viewed by 13518

Special Issue Editors

Dr. Kristin Carpenter

E-Mail Website
Guest Editor
Welding Research Engineering Group, Department of Mechanical, Materials, Mechatronic and Biomedical Engineering, Faculty of Engineering and Information Sciences, University of Wollongong, Wollongong, NSW 2522, Australia
Interests: wire arc additive manufacturing; metallurgy; structure-property relationships; welding; welding fume hazards; steels; hastelloy alloys; and microstructural characterization
Prof. Dr. Chen Shen

E-Mail Website
Guest Editor
Shanghai Key Lab of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Interests: wire-arc additive manufacturing; selective laser melting; electron beam selective melting; metallurgy; structure-property relationships; welding; intermetallics; neutron diffraction; microstructural characterization
Dr. Bintao Wu

E-Mail Website
Guest Editor
School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Northfields Avenue, Wollongong, NSW 2522, Australia
College of Shipbuilding Engineering, Harbin Engineering University, Harbin 150001, China
Interests: additive manufacturing; metallurgy; structure-property relationships; welding; microstructural characterization

Special Issue Information

Dear Colleagues,

Wire arc-based additive manufacturing (WAAM) has been a very active field of research in the last few decades. A key feature of WAAM is its ability to fabricate large scale metallic components at relatively high deposition rates, yet at low equipment costs. Significant progress has been made in understanding and improving metallurgical and material properties and process control of WAAM-produced metallic components.

This Special Issue on “Wire Arc Additive Manufacturing (WAAM) of metallic materials” intends to collect the latest developments in this field by well-known authors who have contributed significantly in the development, design and process improvements for producing metallurgically sound, defect-free, metallic components via WAAM. Metallic components may include, but are not limited to, Ni-based alloys, Al-based alloys, ferrous alloys, intermetallic systems and high entropy alloys.

Topics addressed in the Special Issue may include, but are not limited to:

  • Process development;
  • Path Planning, design and programming;
  • Process modeling;
  • Online control/process monitoring;
  • Industrial applications;
  • Robotic WAAM systems;
  • Metallurgical characterization;
  • Large-scale metallic components.

Dr. Kristin Carpenter
Prof. Dr. Chen Shen
Dr. Bintao Wu
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Wire Arc Additive Manufacturing (WAAM)
  • process monitoring
  • path planning
  • 3D slicing and programming
  • metallurgical characterization
  • welding-based deposition
  • metallic components

Published Papers (4 papers)

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Research

12 pages, 2961 KiB  
Article
Improvement of the Fatigue Resistance of Super Duplex Stainless-Steel (SDSS) Components Fabricated by Wire Arc Additive Manufacturing (WAAM)
by Andrew Sales, Andrei Kotousov, Egon Perilli and Ling Yin
Metals 2022, 12(9), 1548; https://doi.org/10.3390/met12091548 - 19 Sep 2022
Cited by 8 | Viewed by 2340
Abstract
This study aimed to improve the overall fatigue properties of WAAM-produced SDSS by changing the interpass temperatures. Micro-computed tomography was used to quantitatively characterise the internal defects, such as porosity, in large-volume WAAM-fabricated SDSS materials. An increase in the interpass temperature led to [...] Read more.
This study aimed to improve the overall fatigue properties of WAAM-produced SDSS by changing the interpass temperatures. Micro-computed tomography was used to quantitatively characterise the internal defects, such as porosity, in large-volume WAAM-fabricated SDSS materials. An increase in the interpass temperature led to a reduction in the ferrite phase balance by up to 20%. The fatigue anisotropy was still evident, but the fatigue limit in the weakest (transverse) direction was increased to 250 MPa or by approximately 40%. Meanwhile, the increased interpass temperature had no significant effect on fatigue resistance in the longitudinal direction. This study suggests that the interpass temperature can be critical for both achieving isotropic mechanical properties and increasing fatigue life of structural components fabricated with the WAAM method. Full article
(This article belongs to the Special Issue Wire Arc Additive Manufacturing of Metallic Components)
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15 pages, 13742 KiB  
Article
On the Effect of Heat Input and Interpass Temperature on the Performance of Inconel 625 Alloy Deposited Using Wire Arc Additive Manufacturing–Cold Metal Transfer Process
by Chengxun Zhang, Zhijun Qiu, Hanliang Zhu, Zhiyang Wang, Ondrej Muránsky, Mihail Ionescu, Zengxi Pan, Jiangtao Xi and Huijun Li
Metals 2022, 12(1), 46; https://doi.org/10.3390/met12010046 - 25 Dec 2021
Cited by 15 | Viewed by 3898
Abstract
Relatively high heat input and heat accumulation are treated as critical challenges to affect the qualities and performances of components fabricated by wire arc additive manufacturing (WAAM). In this study, various heat inputs, namely 276, 552 and 828 J/mm, were performed to fabricate [...] Read more.
Relatively high heat input and heat accumulation are treated as critical challenges to affect the qualities and performances of components fabricated by wire arc additive manufacturing (WAAM). In this study, various heat inputs, namely 276, 552 and 828 J/mm, were performed to fabricate three thin-wall Inconel 625 structures by cold metal transfer (CMT)-based WAAM, respectively, and active interpass cooling was conducted to limit heat accumulation. The macrostructure, microstructure and mechanical properties of the produced components by CMT were investigated. It was found that the increased heat input can deteriorate surface roughness, and the size of dendrite arm spacing increases with increasing heat input, thus leading to the deterioration of mechanical properties. Lower heat input and application of active interpass cooling can be an effective method to refine microstructure and reduce anisotropy. This study enhances the understanding of interpass temperature control and the effectiveness of heat inputs for Inconel 625 alloy by WAAM. It also provides a valuable in situ process for microstructure and mechanical properties’ refinement of WAAM-fabricated alloys and the control of heat accumulation for the fabrication of large-sized structures for future practical applications. Full article
(This article belongs to the Special Issue Wire Arc Additive Manufacturing of Metallic Components)
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17 pages, 11122 KiB  
Article
Effect of Sigma Phase in Wire Arc Additive Manufacturing of Superduplex Stainless Steel
by Odd M. Akselsen, Ruben Bjørge, Håkon Wiik Ånes, Xiaobo Ren and Bård Nyhus
Metals 2021, 11(12), 2045; https://doi.org/10.3390/met11122045 - 17 Dec 2021
Cited by 3 | Viewed by 2795
Abstract
In the present study, the thermal program in wire and arc additive manufacturing has been varied in terms of heat input and interpass temperature. Three walls were completed with subsequent Charpy V impact toughness and crack-tip opening displacement fracture toughness, together with a [...] Read more.
In the present study, the thermal program in wire and arc additive manufacturing has been varied in terms of heat input and interpass temperature. Three walls were completed with subsequent Charpy V impact toughness and crack-tip opening displacement fracture toughness, together with a detailed microstructure characterization using light microscopy and scanning and transmission electron microscopy. The results clearly demonstrate that the formation of sigma phase may deteriorate the toughness of superduplex components. Such formation may take place under prolonged cooling time, which may occur when subsequent passes are deposited with too high interpass temperatures. This transformation behavior may limit the productivity in additive manufacturing of such steels and care must be taken in selection of proper combination of arc energy and interpass temperature. Full article
(This article belongs to the Special Issue Wire Arc Additive Manufacturing of Metallic Components)
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15 pages, 10661 KiB  
Article
Influence of Post-Deposition Heat Treatments on the Microstructure and Tensile Properties of Ti-6Al-4V Parts Manufactured by CMT-WAAM
by Lexuri Vazquez, Maria Nieves Rodriguez, Iker Rodriguez and Pedro Alvarez
Metals 2021, 11(8), 1161; https://doi.org/10.3390/met11081161 - 22 Jul 2021
Cited by 21 | Viewed by 3241
Abstract
Cold metal transfer (CMT)-based wire and arc additive manufacturing (WAAM) of Ti-6Al-4V alloy has been investigated to manufacture walls with two different building strategies. This study focuses on the influence of the application of thermal treatments on the resulting microstructure and mechanical properties. [...] Read more.
Cold metal transfer (CMT)-based wire and arc additive manufacturing (WAAM) of Ti-6Al-4V alloy has been investigated to manufacture walls with two different building strategies. This study focuses on the influence of the application of thermal treatments on the resulting microstructure and mechanical properties. Deep microstructural analysis revealed different grades of growth of lamellae α phase after several thermal treatments at different temperatures, which lead to different tensile mechanical properties and better strength and ductility balance compared to the as-built condition. Results are compared with equivalent forged and casting standards and the state of the art for WAAM of Ti-6Al-4V alloy. At temperatures of 920 °C, anisotropy was maintained and elongation increased by 70% while yield strength and UTS was slightly decreased by 8%. Full article
(This article belongs to the Special Issue Wire Arc Additive Manufacturing of Metallic Components)
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